Air bag module

ABSTRACT

An air bag module includes an inflator for generating gas and an air bag deployable upon generation of gas by the inflator. The module further includes a container for housing the air bag and inflator therein. Preferably, the container is integrally molded as one piece and includes at least two spaced apart integral living hinges. Preferably, the container has a clamshell construction including a first half and a second half pivotally connected to each other by a closure hinge portion. The container preferably includes deployment end portions opposite the closure hinge portion which are releasably connected to each other. Preferably, at least one of the deployment end portions is pivotally connected to the container.

This invention relates to an air bag module for use in a vehicle.

BACKGROUND OF THE INVENTION

Conventional air bag module designs require a rigid housing which isanchored to a vehicle body and which houses and supports an inflator anda folded air bag. The housing is typically formed of a sturdy rigidmaterial, such as a stamped, drawn or cast metal. The air bag modulealso typically includes a separate plastic molded cover attached to thehousing. The cover typically includes weakened integrally formed tearseams which break open to permit deployment of the air bag therethrough.Prior art covers are typically generally flat due to difficulty inmanufacturing when the molded shape of the cover includes complexcurvatures resulting in a cover which is difficult to remove from themold. In addition the prior art covers are difficult to stretch over theair bag and around or within a housing for attachment thereto. Thus,prior art modules have the shortcoming of requiring multiple componentsfastened together to house the inflator and air bag therein.

Air bag modules are now being contemplated for use in vehicle locationshaving narrow space constraints, such as vehicle seats, doors, roofs orother side structure. Thus, it is continually desirable to reduce thesize and weight of the air bag module to improve packaging.

SUMMARY OF THE INVENTION

This invention provides an improved air bag module which preferably iseasy to manufacture and assemble. The air bag module preferably includesa molded container for housing the air bag and inflator and having ashape which is easy to manufacture by molding and easily removable fromthe mold. Advantageously, this invention eliminates the rigid housing topreferably provide a lightweight module which is easily adaptable forpackaging in vehicle locations with narrow or odd-shaped packagingconstraints, such as a vehicle seat.

These advantages are accomplished in a preferred embodiment of theinvention by providing an air bag module including an inflator forgenerating gas, an air bag deployable upon generation of gas by theinflator, and a container for housing the air bag and inflator therein.Preferably, the container is integrally molded as one piece and includesat least two spaced apart integral living hinges. The container ispreferably a clamshell container including first and second halves and abendable closure hinge portion pivotally connecting the first and secondhalves. Preferably, the clamshell container includes an additional hingeportion located on one of the halves, the hinges enabling movement ofthe clamshell container between an open condition for receiving the airbag and inflator therein and a closed condition defining a substantiallyenclosed volume for housing the air bag and inflator.

In a preferred form, the first and second halves of the clamshellcontainer each include a deployment end portion opposite the closurehinge portion with deployment end portions being releasably connected toeach other. Upon air bag deployment, the deployment end portions breakapart from each other to permit deployment of the air bag therebetween.The deployment end portions are preferably connected to each other byheat staking or ultrasonic welding. It is preferred that at least one ofthe deployment end portions is hingedly connected to the clamshellcontainer by a deployment hinge portion. Preferably, the deploymenthinge portion is stronger than the releasable connection between thedeployment end portions such that upon air bag deployment, the inflatingair bag breaks apart the deployment end portions and the deploymenthinge portion remains intact and permits rotation of the deployment endportion.

In accordance with another preferred aspect of the invention, a methodof making an air bag module includes the steps of molding a one-piececontainer for housing the air bag and inflator, the container beingmolded in an open condition having a least two integral living hingeportions enabling all portions of the container to have a positive dieangle for easy removal from a mold, and the hinge portions pivotallyconnecting the container for movement to a closed condition defining asubstantially enclosed volume.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention is described below, by way ofexample only, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a vehicle interior partially broken awayand including an air bag module in an undeployed condition;

FIG. 2 is a view similar to FIG. 1 but showing the air bag module in adeployed condition;

FIG. 3 is a section as viewed along line 3--3 of FIG. 1 and showing theair bag module in the undeployed condition and showing the initialopening of a clamshell container in phantom;

FIG. 4 is a section as viewed along line 4--4 of FIG. 2 and showing theair bag module in the deployed condition;

FIG. 5 is a partially exploded perspective view of the module;

FIG. 6 is a perspective view showing the air bag module in an assembledcondition; and

FIG. 7 is a section view similar to FIG. 3, but showing an alternateembodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, it is seen that a vehicle 12 includes a door 14having a movable window is mounted thereon. An interior 16 of thevehicle includes an inner door panel 17 and a seat 18 for a vehicleoccupant (not shown), the seat 18 having a seat bottom 19 and an upperseat back 20. The seat back 20 includes a rigid seat frame 21,preferably being metal, and encompassed within the seat back The seatback 20 is preferably formed of a foam material 23 covered by fabricseat material 24. The seat back 20 preferably includes a verticallyextending frangible seat seam 27 proximate the inner door panel 17.

FIG. 5 best illustrates the component parts of a complete air bag module30 located within the seat back 20. The module 30 generally includes aninflator 40, an air bag 50 for inflation upon generation of gas by theinflator 40, a clamshell container 60 for housing the inflator 40 andair bag 50 therein, and a mounting bracket 80 for mounting the module 30to the seat frame 21.

As best shown in FIG. 5, the inflator 40 may be of any conventionalconstruction which contains chemicals for igniting to generate gas fordischarge upon the existence of predetermined vehicle 12 conditions. Theinflator 40 preferably has a hybrid construction including an axiallyelongated cylindrical inflator body 41 having a plain end 42 and anopposite discharge end 43 including ports 44 through which inflator gasis discharged in a thrust neutral manner to inflate the air bag 50. Anaxially elongated inflator rod 45 having a threaded end portion 46preferably extends from the discharge end 43 of the inflator 40 forattachment of the mounting bracket 80, as described further hereinafter.The elongated axis of the inflator 40 is preferably generally verticaland generally parallel with the seat back 20 when the module 30 ismounted in the seat 18.

As best shown in FIG. 5, the air bag 50 is 20 made of any conventionalfabric material which is suitable for air bag construction. The air bag50 includes a folded main body portion 51 which is inflatable to atubular shape upon the discharge of inflator gas. The air bag 50 alsoincludes a neck portion 52 preferably being an extension of the air bagfabric material. The neck portion 52 includes first and second opposingside openings 53, 54 sized for receiving the inflator 40 therethrough.Preferably, the first side opening 53 is sized larger than the secondside opening 54. Preferably, the first side opening 53 is sized forreceiving the larger plain end 42 of the inflator 40 therein. Alsopreferably, the second side opening 54 is tapered and is sized for aninterference fit with a tapered spacer 77 disposed on the inflator 40,as described further hereinafter. The neck portion 52 also defines aninner air bag opening through which inflator gas passes to inflate themain body portion 51 of the air bag 50. It will be appreciated that theair bag 50 including the main body portion 51 and the neck portion 52may be made of a single piece of fabric or several fabric panels joinedtogether.

The main body portion 51 of the air bag 50 preferably includes upper andlower longitudinally extending folds (not shown) such that the main bodyportion 51 is folded to a height approximately equal to a height of theneck portion 52. The main body portion 51 is then preferably folded intoa plurality of accordion-style pleat folds (not shown) for storagewithin the clamshell container 60. It will be appreciated, however, thatother fold arrangements designed to conform to the shape of theclamshell container 60 are also contemplated. While the air bag 50 inFIG. 2 is preferably shown as a longitudinally elongated air bag 50positioned for protecting the torso portion of an occupant (not shown),it will be appreciated that the air bag 50 may also be positioned higherin the seat back 20 to protect the head portion of the occupant or mayhave a greater total height for protection of both the torso and headportion of the occupant.

As best shown in FIGS. 5 and 6, the module 30 further includes afoldable clamshell container 60 which houses the folded air bag 50 priorto inflation. Advantageously, the clamshell container 60 also preferablyhouses the inflator 40 and the mounting bracket 80 prior to air bagdeployment, thus eliminating the need for a rigid housing and a separatecover. As best shown in FIG. 5, the clamshell container 60 includes afirst half 61 and a second half 62 and an integral, bendable, thinclosure hinge portion 63 pivotally connecting the first and secondhalves 61, 62.

As best shown in FIG. 5, the clamshell container 60 has a generallyplanar, open condition in which the first and second halves 61, 62 eachextend outwardly from the closure hinge portion 63. The first and secondhalves 61, 62 are pivotally connected by the closure hinge portion 63.The closure hinge portion 63 preferably permits pivotal movement of thefirst and second halves 61, 62 at least 180 degrees relative each other.Thus, the clamshell container 60 is foldable to a closed condition inwhich the first and second halves 61, 62 are positioned atop each otheras best shown in FIGS. 3 and 6.

As best shown in FIG. 5, the clamshell container 60 has an outer surface64 and an inner surface 65. The first and second halves 61, 62 of theclamshell container 60 each preferably have a generally half-cylindricalshape further defined by perimetric edges 66 including hinged edges 67integrally attached to the closure hinge portion 63, free end edges 68and deployment edges 69.

As best shown in the closed condition in FIGS. 3 and 6, the clamshellcontainer 60 includes an outboard side wall 70 on the first half 61, andan inboard side wall 71 on the second half 62, and two pairs of opposingend walls 72. Preferably, the lower pair of end walls 72 cooperativelydefines an inflator opening 73 through which an electrical connector(not shown) for the inflator 40 extends when the module 30 is assembled.The inboard side wall 71 on the second half 62 preferably includes a setof fastener apertures 74 for receiving mounting fasteners 81 of themounting bracket 80 therethrough, as described further hereinafter. Thewalls 70, 71, 72 of the clamshell container 60 cooperatively define asubstantially enclosed volume in which the air bag 50, inflator 40 andmounting bracket 80 are stored prior to air bag deployment.

The clamshell container 60 includes a first deployment end portion 90preferably located longitudinally forward on the first half 61 and asecond deployment end portion 91 preferably located longitudinallyforward on the second half 62. The first and second deployment endportions 90, 91 preferably each include a laterally extending portion 93and an outwardly projecting lip portion 94. The lip portions 94 of thedeployment end portions 90, 91 are releasably connected to each otherprior to air bag deployment. Upon air bag inflation, the air bag 50forcibly separates the lip portions 94 of the first and seconddeployment end portions 90, 91 from each other and deploys therebetween.Preferably, the lip portions 94 of the deployment end portions 90, 91are connected to each other by ultrasonic welding or by heat staking tohold the clamshell container 60 in the closed condition. It will furtherbe appreciated that the deployment end portions 90, 91 may also beconnected by any other suitable means, such as mechanical fasteners orsnap-fitted attachment with integrally formed mating features on thefirst and second halves 61, 62.

As best shown in FIGS. 3, 4 and 5, the clamshell container 60 includes abendable, thin deployment hinge portion 95 pivotally connecting thefirst deployment end portion 90 to the first half 61 of the clamshellcontainer 60. The deployment hinge portion 95 preferably permits pivotalmovement of the first deployment end portion 90 approximately 90 degreesrelative the outboard side wall 70 of the first half 61 of the clamshellcontainer 60. Preferably the deployment hinge portion 95 extends alongthe entire height of the first half 61 of the clamshell container 60.However, it will be appreciated that the deployment hinge portion 95 mayonly partially extend along the height of the clamshell container 60,especially when the first half 61 has additional complex curvatures. Asbest shown in FIG. 5, the clamshell container 60 is preferablyintegrally molded as one piece in the open condition wherein the closurehinge portion 63 and the deployment hinge portion 95 are rotated opensuch that the clamshell container 60 has positive die angles for easyremoval from the mold.

It is critical that the integral connection of the deployment hingeportion 95 to the first half 61 be stronger than the connection betweenthe lip portions 94. Thus, upon air bag deployment, the lip portions 94should separate from each other and the deployment hinge portion 95should remain attached to the first half 61 of the clamshell container60.

The entire clamshell container 60 is preferably integrally molded as asingle component from a suitable polymeric material. Preferably, theclamshell container 60 is molded as a single component in the opencondition as shown in FIG. 5. Advantageously, the clamshell container 60is easily removable from the mold due to its generally planar, outwardlyextending halves 61, 62 interconnected by the bendable closure hingeportion 63. The clamshell container 60 is also easily removable from themold due to the deployment hinge portion 95 which permits the firstdeployment end portion 90 to be molded in a position with a positive dieangle. It will further be appreciated that the deployment hinge portion95 and the closure hinge portion 63 are each preferably formed as oneintegral piece with the clamshell container 60 as integral livinghinges.

As best shown in FIG. 5, the module 30 preferably includes a mountingbracket 80 having a vertically elongated bracket portion 82 andlaterally bent first and second apertured bracket ends 83, 84. The firstapertured bracket end 83 is sized for receiving the plain end 42 of theinflator 40 therein and the second apertured bracket end 84 is sized forreceiving the elongated inflator rod 45 of the inflator 40 therein. Themounting bracket 80 further includes a set of outwardly projectingmounting fasteners 81 connected to the elongated bracket portion 82 andspaced for alignment with the fastener apertures 74 in the second half62 of the clamshell container 60. The mounting bracket 80 has a heightless than that of the inflator 40 including the elongated inflator rod45 such that the threaded end portion 46 of the elongated inflator rod45 extends out beyond the second apertured bracket end 84 for attachmentof an end nut 85 thereto to secure the mounting bracket 80 to theinflator 40. The mounting fasteners 81 of the mounting bracket 80 aresuitably attached to any vehicle 12 structure, such as the seat frame 21or a suitable projection welded to the seat frame 21. Thus, the entiremodule 30 can be easily removably mounted on the vehicle 12 by the useof the mounting bracket 80 with mounting fasteners 81 and secured inplace, such as by mounting nuts 86.

Preferably, an apertured spacer 77 is sized for receiving the elongatedinflator rod 45 therethrough and is positioned between the secondapertured bracket end 84 and the discharge end 43 of the inflator 40 forpositioning the mounting bracket 80 relative the inflator 40.Preferably, the spacer 77 has an upper tapered end 78 corresponding withan angled portion 87 on the elongated bracket portion 82. It will beappreciated that the spacer 77 including the tapered end 78 is disposedon the inflator 40 by slip-fitted connection, but could also beintegrally formed on the inflator 40 or could threadably engage theinflator 40.

The tapered end 78 of the spacer 77 and the tapered second side opening54 of the neck portion 52 of the air bag 50 cooperatively ensure properassembly of the air bag 50 on the inflator 40 and cooperatively providepositive location of the air bag 50 on the inflator 40 during deploymentas will now be described. To assemble the air bag 50 to the inflator 40,the tapered spacer 77 is slipped onto the elongated inflator rod 45 andthen the elongated inflator rod 45, tapered spacer 77 and discharge end43 of the inflator 40 must be axially inserted into the larger firstside opening 53 of the neck portion 52 of the air bag 50. Insertion iscontinued until the tapered end 78 of the spacer 77 is tightly capturedand positioned within the tapered second side opening 54 of the neckportion 52 of the air bag 50. The larger plain end 42 of the air bag 50is sized larger than the tapered second side opening 54, thus ensuringthat the air bag 50 cannot be attached to the inflator 40 upside down.While the air bag 50 shown in the drawings is generally symmetrical,this feature is especially useful with an air bag which is not generallysymmetrical and which is also contemplated for use with this invention.Upon air bag deployment, the interference fit between the tapered secondside opening 54 of the air bag 50 and the tapered end 78 of the spacer77 of the inflator 40 maintains the proper location of the air bag 50 onthe inflator 40 by reducing axial sliding movement of the air bag 50relative the inflator 40 and also by reducing rotation of the air bag 50about the inflator 40 during the discharge of inflator gas. The angledportion 87 on the mounting bracket 80 also additionally ensures properinstallation of the mounting bracket 80 relative the air bag 50 andinflator 40 since the angled portion 87 of the mounting bracket 80 mustbe aligned with the tapered end 78 of the spacer 77 and closely capturesthe air bag 50 between the spacer 77 and angled portion 87 in theassembled condition described below.

Referring to FIGS. 5 and 6, the module 30 is assembled as follows.Initially, an air bag subassembly is assembled which preferably includesthe air bag 50, the mounting bracket 80, the spacer 77, and the inflator40. First, the elongated inflator rod 45 of the inflator 40 is axiallyslipped through the apertured spacer 77. Next, the inflator 40, with theelongated inflator rod 45 and spacer 77 leading, are slid through thefirst side opening 53 of the neck portion 52 of the air bag 50 until thetapered end 78 of the spacer 77 achieves an interference fit with thetapered second side opening 54, as described in detail above, andwherein the threaded end portion 46 of the elongated inflator rod 45extends out beyond the second side opening 54 and the discharge end 43of the inflator 40 is positioned within the neck portion 52 fordischarging gas into the main body portion 51 of the air bag 50. Next,the first apertured bracket end 83 is axially slid up over the plain end42 of the inflator 40 until the second apertured bracket end 84 is abovethe elongated inflator rod 45. Next the second apertured bracket end 84is axially pushed onto the elongated inflator rod 45 of the inflator 40until the second apertured bracket end 84 engages the spacer 77 toprevent the first apertured bracket end 83 from slipping off the plainend 42. Next, the end nut 85 is secured to the threaded end portion 46of the elongated inflator rod 45 to securely attach and position themounting bracket 80 relative the inflator 40 and air bag 50. It willfurther be appreciated that the first and second apertured bracket ends83, 84 capture the air bag 50 therebetween to additionally position theair bag 50 relative the inflator 40. Finally, the air bag 50 is foldedinto a compact shape preferably including upper and lower longitudinallyextending folds and a plurality of accordion-type pleat folds tocomplete the air bag subassembly.

The module 30 assembly is easily completed as follows. As best shown inFIG. 5, the clamshell container 60 is placed in the open condition andthe mounting fasteners 81 on the mounting bracket 80 are matably alignedwith the fastener apertures 74 on the second half 62 of the clamshellcontainer 60. The air bag subassembly including the air bag 50, theinflator 40 and the mounting bracket 80, is placed into the second half62 of the clamshell container 60 with the mounting fasteners 81 insertedout through the fastener apertures 74. It will be appreciated that thefolded air bag 50, inflator 40 and mounting bracket 80 are easily placedwithin the clamshell container 60 in the open condition since theclosure hinge portion 63 enables the first and second halves 61, 62 tobe opened 180 degrees apart in a generally planar condition.

Next, the first half 61 of the clamshell container 60 is simply foldedover approximately 180 degrees and positioned atop the second half 62 asshown in FIG. 6. The first deployment end portion 90 is folded overapproximately 90 degrees and closed and matably aligned with the seconddeployment end portion 91 such that the lip portions 94 engage eachother. To complete the module assembly, the lip portions 94 of the firstand second deployment end portions 90, 91 are then releasably connectedto each other, such as by ultrasonic welding, to maintain the clamshellcontainer 60 in the closed condition until air bag deployment. In theclosed condition, the clamshell container 60 maintains the air bag 50 inthe folded condition. Also in the closed condition, the clamshellcontainer 60 substantially encapsulates the air bag 50, inflator 40 andmounting bracket 80 and prevents entry of foreign articles into themodule 30. As best shown in FIG. 6, the respective perimetric edges 66including the hinged, end and deployment edges 67, 68, 69 of the firstand second halves 61, 62 are aligned with each other and substantiallyabut each other when the clamshell container 60 is in the closedcondition.

As best shown in FIG. 1, the module 30 may be attached to any suitablevehicle 12 structure and is particularly well-adapted for use in narrowvehicle locations with limited space such as the seat back 20 or seatbottom 19 or vehicle side structure. The module 30 is preferablyattached to the seat frame 21 of the seat back 20 by simply securing themounting fasteners to the seat frame 21, such as by use of mounting nuts86.

Upon the sensing of predetermined vehicle 12 conditions, the inflator 40generates inflator gas out through the ports 44 on the discharge end 43and into the main body portion 51 of the air bag 50. The inflating airbag 50 forcibly breaks apart and separates the lip portions 94 of thefirst and second deployment end portions 90, 91 such that the air bag 50can deploy between the first and second halves 61, 62 of the clamshellcontainer 60. It is desirable that the deployment hinge portion 95 bestronger than the connection of the lip portions 94 such that thedeployment hinge portion 95 does not tear open during air bagdeployment. Thus, the thickness of the deployment hinge portion 95 andthe ultrasonic welding, heat staking or other fastening of the lipportions 94 must be suitably tuned to obtain that objective.

As best shown in FIG. 3, during initial inflation the lip portions 94break apart and the first deployment end portion 90 flaps open androtates about the deployment hinge portion 95 outwardly towards the door14, while the second deployment end portion 91 remains in generally thesame position. Thus, the deployment end portions 90, 91 canadvantageously be used to cooperatively bias and direct initialinflation of the air bag 50 outwardly towards the door 14. In addition,rotation of the first deployment end portion 90 about the deploymenthinge portion 95 creates a greater air bag opening 56 through which theinflating air bag 50 can deploy. Upon further air bag 50 inflation, thefirst and second halves 61, 62 of the clamshell container 60 rotatepartially open about the closure hinge portion 63 for deployment of theair bag 50 therebetween to the fully inflated condition shown in FIGS. 2and 4. During air bag deployment, the interference fit between thetapered second side opening 54 of the air bag 50 and the tapered end 78of the spacer 77 of the inflator 40 maintains the proper location of theair bag 50 on the inflator 40 by reducing axial sliding movement of theair bag 50 relative the inflator 40 and also by reducing rotation of theair bag 50 about the inflator 40 during the discharge of inflator gas.

Advantageously, the clamshell container 60 permits greater flexibilityin packaging such that the clamshell container 60 can be sized toexactly fit the desired size and packaging of the folded air bag 50 andinflator 40 within a narrow vehicle 12 location. It will further beappreciated that the clamshell container 60 is easily molded due to theclosure hinge portion 63 and the deployment hinge portion 95 whichpermit placement of the halves 61, 62 and the first deployment endportion 90, respectively, during molding to a position having a positivedie angle for easy removal from the mold.

It will be understood that a person skilled in the art may makemodifications to the preferred embodiment shown herein within the scopeand intent of the claims. For example, although the clamshell container60 is shown as having two generally half-cylindrical halves 61, 62, itwill be appreciated that the first and second halves 61, 62 may bevirtually any geometric shape. It will further be appreciated that whilethe closure hinge portion 63 and the deployment hinge portion 95 arepreferably shown as one continuous strip, the closure and deploymenthinge portions 63, 95 may also be discontinuous or may extend less thanthe height of the clamshell container 60 in the case of more complexcurvatures. While the first deployment end portion 90 of the clamshellcontainer 60 is preferably rotatable approximately 90 degrees about thedeployment hinge portion 95, it will be appreciated that the firstdeployment end portion 90 may be rotatable more or less than 90 degreesdepending on the amount of rotation desired for achieving a positive dieangle and for directing the air bag 50. Although the preferredembodiment shows the mounting bracket 80 packaged within the clamshellcontainer 60, it will be appreciated that the mounting bracket 80 couldalso be attached to the outside of the clamshell container 60 or thatthe inflator 40 and mounting bracket 80 could be positioned within theneck portion 52 of the air bag 50. It will further be appreciated thatthe mounting bracket 80 and spacer 77 could be eliminated and that themounting fasteners 81 could be mounted directly on the inflator 40 andextend out through the air bag 50 and clamshell container 60 forattachment to the vehicle 12. While the preferred embodiment shows thespacer 77 located upward in the module 30, it will also be appreciatedthat the first and second side openings 53, 54 of the neck portion 52could be switched and the tapered spacer 77 could be located towards thebottom of the module 30.

It will be appreciated that the closure hinge portion 63 and thedeployment hinge portion 95 both advantageously enable easy positioningof the clamshell container 60 within the mold so that positive dieangles can be achieved for ease of removal from the mold. It willfurther be appreciated that the clamshell container 60 may haveadditional living hinge portions positioned between the closure hingeportion 63 and the deployment edges 69 when needed for easy removal ofthe clamshell container 60 from the mold. Advantageously, the closurehinge portion 63 serves the additional purpose of permitting rotation ofthe first and second halves 61, 62 of the clamshell container 60 betweenthe open and closed conditions for easy installation of the air bagsubassembly. Also advantageously the deployment hinge portion 95 servesthe additional purposes of permitting pivotal movement of the firstdeployment end portion 90 for flapping open to provide a wider air bagopening 56 through which the air bag 50 deploys and also for directingthe deploying air bag 50. Thus, it will further be appreciated that thefirst and second deployment end portions 90, 91 may be a larger portionof the clamshell container 60 for providing an even wider air bagopening 56 and for providing additional guidance to the deploying airbag 50.

It will further be appreciated that the second deployment end portion 91may be pivotally connected to the second half 62 of the clamshellcontainer 60 in a similar manner to the first deployment end portion 90.FIG. 7 shows an alternate embodiment of the invention similar to thatshown in FIGS. 1-6, with similar parts denoted by similar numerals.However, the clamshell container 60 includes an additional deploymenthinge portion 95' which pivotally connects the second deployment endportion 91 to the second half 62 of the clamshell container 60.

While the present embodiment has been described as carried out in aspecific embodiment thereof, it is not intended to be limited thereby,but is intended to cover the invention broadly within the scope andspirit of the claims.

What is claimed is:
 1. An air bag module comprising:an inflator forgenerating gas; an air bag deployable upon generation of gas by theinflator: and a container housing the air bag and inflator therein, thecontainer having walls defining a substantially enclosed volume, thecontainer including first and second halves and a bendable closure hingeportion pivotally connecting the first and second halves and thecontainer including an additional hinge portion located on one of thehalves, the hinges enabling movement of the container between an opencondition for receiving the air bag and inflator therein and a closedcondition defining a substantially enclosed volume for housing the airbag and inflator.
 2. An air bag module comprising:an inflator forgenerating gas; an air bag deployable upon generation of gas by theinflator; and a clamshell container having a first half and a secondhalf pivotally connected to each other by a closure hinge portion, theclamshell container housing the air bag and inflator therein, the firstand second halves of the clamshell container each including a deploymentend portion opposite the closure hinge portion, the deployment endportions being releasably connected to each other such that upon air bagdeployment, the deployment end portions break apart from each other topermit deployment of the air bag therebetween, at least one of thedeployment end portions being hingedly connected to the clamshellcontainer by a deployment hinge portion and the deployment hinge portionbeing stronger than the releasable connection between the deployment endportions whereby upon air bag deployment, the inflating air bag breaksapart the deployment end portions and the deployment hinge portionremains intact and permits rotation of the corresponding deployment endportion.
 3. The module of claim 2 wherein the deployment end portionseach include a laterally extending portion and an outwardly protrudinglip portion.
 4. The module of claim 2 wherein the deployment endportions are connected to each other by heat staking.
 5. The module ofclaim 2 wherein the deployment end portions are connected to each otherby ultrasonic welding.
 6. An air bag module comprising:an inflator forgenerating gas; an air bag deployable upon generation of gas by theinflator; and a clamshell container having a first half and a secondhalf pivotally connected to each other by a closure hinge portion, theclamshell container housing the air bag and inflator therein, the firstand second halves each having a forward deployment edge pivotallyconnected thereto whereby upon air bag inflation the forward deploymentedges rotate open for deployment of the air bag therethrough.
 7. The airbag module of claim 6 wherein the first and second halves are shaped forclosely capturing the inflator and air bag therein when the clamshellcontainer is in a closed condition.
 8. An air bag module comprising:aninflator for generating gas; an air bag deployable upon generation ofgas by the inflator; and a clamshell container having a first half and asecond half pivotally connected to each other by a closure hingeportion, the clamshell container housing the air bag and inflatortherein, the first and second halves of the clamshell container eachincluding a deployment edge opposite the closure hinge portion, thedeployment edges of the clamshell container being releasably connectedto each other such that upon air bag deployment, the air bag breaks openand deploys between the deployment edges of the clamshell container, andat least one of the deployment edges being hingedly connected to thecorresponding one of the first and second halves of the clamshellcontainer.
 9. An air bag module comprising:an air bag having a neckportion including axially aligned opposing first and second sideopenings, the second side opening being sized smaller than the firstside opening; and an inflator having opposing first and second inflatorends, the first inflator end being sized larger than the second sideopening and the second inflator end being in interference-fittedengagement with the second side opening, the second side opening beingtapered and the second inflator end being tapered.
 10. An air bag modulecomprising:an inflator for generating gas; an air bag deployable upongeneration of gas by the inflator; and a clamshell container having afirst half and a second half pivotally connected to each other by aclosure hinge portion, the clamshell container housing the air bag andinflator therein, the first and second halves of the clamshell containereach including a deployment end portion opposite the closure hingeportion, and at least one of the deployment end portions being hingedlyconnected to the corresponding one of the first and second halves of theclamshell container.